Transcutaneous analyte sensor

Abstract

The present invention relates generally to systems and methods for measuring an analyte in a host. More particularly, the present invention relates to systems and methods for transcutaneous measurement of glucose in a host.

What is claimed is: 
     
       1. A system for manufacturing a transcutaneous glucose sensor, comprising:
 a plurality of coating stations, wherein the plurality of coating stations are configured to serially deposit a plurality of membrane layers on an elongated conductive body to form a membrane system, wherein the elongated conductive body comprises an electroactive surface, wherein the plurality of coating stations each comprise a vessel for holding a coating solution, wherein at least one station of the plurality of coating stations comprises a solution comprising a biocompatible material, wherein the at least one station is configured to deposit a layer of the biocompatible material to form a biocompatible membrane layer, whereby an uncalibrated transcutaneous glucose sensor is obtained; 
 an automated or semi-automated transport configured to continuously move the elongated conductive body through the plurality of coating stations; 
 a station configured to conduct in vitro sensor testing to obtain in vitro sensor information related to in vitro sensor sensitivity for the uncalibrated transcutaneous glucose sensor; and 
 a processor configured to process the in vitro testing information to produce prior implantation information including a predicted in vivo sensitivity determined from a predictive relationship between in vitro sensor sensitivity and in vivo sensor sensitivity, wherein the processor is configured to associate the uncalibrated transcutaneous glucose sensor with the prior implantation information, wherein the prior implantation information is employed to calibrate the uncalibrated transcutaneous glucose sensor completely without a need for reference glucose values obtained after sensor implantation. 
 
     
     
       2. The system of  claim 1 , further comprising a station for cutting the elongated conductive body to form a plurality of transcutaneous glucose sensors. 
     
     
       3. The system of  claim 1 , wherein the plurality of coating stations comprises a station for curing the plurality of membrane layers. 
     
     
       4. The system of  claim 1 , wherein the plurality of coating stations comprises a station for depositing a coating material to form a layer comprising an enzyme. 
     
     
       5. The system of  claim 1 , wherein the plurality of coating stations comprises a station for depositing a coating material to form a layer configured to block or reduce passage of one or more interferents. 
     
     
       6. The system for  claim 1 , wherein the elongated conductive body comprises at least one material selected from the group consisting of: platinum, platinum-iridium, palladium, graphite, gold, carbon, conductive polymer, and alloys or combinations thereof. 
     
     
       7. The system of  claim 1 , wherein the elongated conductive body comprises a plated wire. 
     
     
       8. The system of  claim 1 , wherein the automated or semi-automated mechanism comprises a reel-to-reel mechanism. 
     
     
       9. The system of  claim 1 , wherein the automated or semi-automated mechanism comprises a robot driven mechanism. 
     
     
       10. The system of  claim 1 , wherein the automated or semi-automated mechanism is configured to continuously move a plurality of elongated conductive bodies. 
     
     
       11. The system of  claim 1 , wherein the transcutaneous glucose sensor is configured for implantation in a host and is configured to provide continuous measurement of glucose concentration in the host. 
     
     
       12. The system of  claim 1 , wherein at least one of the plurality of coating stations is configured to remove a portion of an insulator over the elongated conductive body to form a window, whereby a portion of the elongated conductive body is exposed. 
     
     
       13. The system of  claim 1 , wherein the transcutaneous glucose sensor is configured to function for 3 to 14 days. 
     
     
       14. The system of  claim 1 , wherein the transcutaneous sensor comprises an in vivo portion and an ex vivo portion.